Commission Implementing Decision (EU) 2016/1032 of 13 June 2016 establishing best available techniques (BAT) conclusions, under Directive 2010/75/EU of the European Parliament and of the Council, for the non-ferrous metals industries (notified under document C(2016) 3563) (Text with EEA relevance) (c. 1032)

ANNEX U.K. BAT CONCLUSIONS FOR THE NON-FERROUS METALS INDUSTRIES

1.2. BAT CONCLUSIONS FOR COPPER PRODUCTION U.K.

1.2.1. Secondary materials U.K.

BAT 20. In order to increase the secondary materials’ recovery yield from scrap, BAT is to separate non-metallic constituents and metals other than copper by using one or a combination of the techniques given below. U.K.

	Technique
a	Manual separation of large visible constituents
b	Magnetic separation of ferrous metals
c	Optical or eddy current separation of aluminium
d	Relative density separation of different metallic and non-metallic constituents (using a fluid with a different density or air)

1.2.2. Energy U.K.

BAT 21. In order to use energy efficiently in primary copper production, BAT is to use one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Optimise the use of the energy contained in the concentrate using a flash smelting furnace	Only applicable for new plants and for major upgrades of existing plants
b	Use the hot process gases from the melting stages to heat up the furnace charge	Only applicable to shaft furnaces
c	Cover the concentrates during transport and storage	Generally applicable
d	Use the excess heat produced during the primary smelting or converting stages to melt secondary materials containing copper	Generally applicable
e	Use the heat in the gases from anode furnaces in a cascade for other processes such as drying	Generally applicable

BAT 22. In order to use energy efficiently in secondary copper production, BAT is to use one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Reduce the water content of the feed material	Applicability is limited when the moisture content of the materials is used as a technique to reduce diffuse emissions
b	Produce steam by recovering excess heat from the smelting furnace to heat up the electrolyte in refineries and/or to produce electricity in a co-generation installation	Applicable if an economically viable demand of steam exists
c	Melt scraps using the excess heat that is produced during the smelting or converting process	Generally applicable
d	Holding furnace between processing stages	Only applicable for batch-wise operated smelters where a buffer capacity of molten material is required
e	Preheat the furnace charge using the hot process gases from the melting stages	Only applicable to shaft furnaces

BAT 23. In order to use energy efficiently in electrorefining and electrowinning operations, BAT is to use a combination of the techniques given below. U.K.

	Technique	Applicability
a	Apply insulation and covers to electrolysis tanks	Generally applicable
b	Addition of surfactants to the electrowinning cells	Generally applicable
c	Improved cell design for lower energy consumption by optimisation of the following parameters: space between anode and cathode, anode geometry, current density, electrolyte composition and temperature	Only applicable for new plants and for major upgrades of existing plants
d	Use of stainless steel cathode blanks	Only applicable for new plants and for major upgrades of existing plants
e	Automatic cathode/anode changes to achieve an accurate placement of the electrodes into the cell	Only applicable for new plants and for major upgrades of existing plants
f	Short circuit detection and quality control to ensure that electrodes are straight and flat and that the anode is exact in weight	Generally applicable

1.2.3. Air emissions U.K.

BAT 24. In order to reduce secondary emissions to air from furnaces and auxiliary devices in primary copper production and to optimise the performance of the abatement system, BAT is to collect, mix and treat secondary emissions in a centralised off-gas cleaning system. U.K.

Description U.K.

Secondary emissions from various sources are collected, mixed, and treated in a single centralised off-gas cleaning system, designed to effectively treat the pollutants present in each of the flows. Care is taken not to mix streams which are not chemically compatible and to avoid undesirable chemical reactions among the different collected flows.

Applicability U.K.

The applicability may be limited for existing plants by their design and layout.

1.2.3.1. Diffuse emissions U.K.

BAT 25. In order to prevent or reduce diffuse emissions from pretreatment (such as blending, drying, mixing, homogenisation, screening and pelletisation) of primary and secondary materials, BAT is to use one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Use enclosed conveyers or pneumatic transfer systems for dusty materials	Generally applicable
b	Carry out activities with dusty materials such as mixing in an enclosed building	For existing plants, application may be difficult due to the space requirements
c	Use dust suppression systems such as water cannons or water sprinklers	Not applicable for mixing operations carried out indoors. Not applicable for processes that require dry materials. The application is also limited in regions with water shortages or with very low temperatures
d	Use enclosed equipment for operations with dusty material (such as drying, mixing, milling, air separation and pelletisation) with an air extraction system connected to an abatement system	Generally applicable
e	Use an extraction system for dusty and gaseous emissions, such as a hood in combination with a dust and gas abatement system	Generally applicable

BAT 26. In order to prevent or reduce diffuse emissions from charging, smelting and tapping operations in primary and secondary copper smelters and from holding and melting furnaces, BAT is to use a combination of the techniques given below. U.K.

a Description of the technique is given in Section 1.10.
	Technique	Applicability
a	Briquetting and pelletisation of raw materials	Applicable only when the process and the furnace can use pelletised raw materials
b	Enclosed charging system such as single jet burner, door sealinga, closed conveyers or feeders equipped with an air extraction system in combination with a dust and gas abatement system	The jet burner is applicable only for flash furnaces
c	Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation	Generally applicable
d	Capture hood/enclosures at charging and tapping points in combination with an off-gas abatement system (e.g. housing/tunnel for ladle operation during tapping, and which is closed with a movable door/barrier equipped with a ventilation and abatement system)	Generally applicable
e	Encapsulate the furnace in vented housing	Generally applicable
f	Maintain furnace sealing	Generally applicable
g	Hold the temperature in the furnace at the lowest required level	Generally applicable
h	Boosted suction systemsa	Generally applicable
i	Enclosed building in combination with other techniques to collect the diffuse emissions	Generally applicable
j	Double bell charging system for shaft/blast furnaces	Generally applicable
k	Select and feed the raw materials according to the type of furnace and abatement techniques used	Generally applicable
l	Use of lids on throats of rotary anode furnace	Generally applicable

BAT 27. In order to reduce diffuse emissions from Peirce-Smith converter (PS) furnace in primary and secondary copper production, BAT is to use a combination of the techniques given below. U.K.

a Description of the technique is given in Section 1.10.
	Technique
a	Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation
b	Oxygen enrichment
c	Primary hood over the converter opening to collect and transfer the primary emissions to an abatement system
d	Addition of materials (e.g. scrap and flux) through the hood
e	System of secondary hoods in addition to the main one to capture emissions during charging and tapping operations
f	Furnace located in enclosed building
g	Apply motor-driven secondary hoods, to move them according to the process stage, to increase the efficiency of the collection of secondary emissions
h	Boosted suction systemsa and automatic control to prevent blowing when the converter is ‘rolled out’ or ‘rolled in’

BAT 28. In order to reduce diffuse emissions from a Hoboken converter furnace in primary copper production, BAT is to use a combination of the techniques given below. U.K.

a Description of the technique is given in Section 1.10.
	Technique
a	Operate furnace and gas route under negative pressure during charging, skimming and tapping operations
b	Oxygen enrichment
c	Mouth with closed lids during operation
d	Boosted suction systemsa

BAT 29. In order to reduce diffuse emissions from the matte conversion process, BAT is to use a flash converting furnace. U.K.

Applicability U.K.

Applicable only to new plants or major upgrades of existing plants.

BAT 30. In order to reduce diffuse emissions from a top-blown rotary converter (TBRC) furnace in secondary copper production, BAT is to use a combination of the techniques given below. U.K.

a Description of the technique is given in Section 1.10.
	Technique	Applicability
a	Operate the furnace and gas route under negative pressure and at a sufficient gas extraction rate to prevent pressurisation	Generally applicable
b	Oxygen enrichment	Generally applicable
c	Furnace located in enclosed building in combination with techniques to collect and transfer diffuse emissions from charging and tapping to an abatement system	Generally applicable
d	Primary hood over the converter opening to collect and transfer the primary emissions to an abatement system	Generally applicable
e	Hoods or crane integrated hood to collect and transfer the emissions from charging and tapping operations to an abatement system	For existing plants, a crane integrated hood is only applicable to major upgrades of the furnace hall
f	Addition of materials (e.g. scrap and flux) through the hood	Generally applicable
g	Boosted suction systema	Generally applicable

BAT 31. In order to reduce diffuse emissions from copper recovery with a slag concentrator, BAT is to use the techniques given below. U.K.

	Technique
a	Dust suppression techniques such as a water spray for handling, storage and crushing of slag
b	Grinding and flotation performed with water
c	Delivery of the slag to the final storage area via hydro transport in a closed pipeline
d	Maintain a water layer in the pond or use a dust suppressant such as lime milk in dry areas

BAT 32. In order to reduce diffuse emissions from copper-rich slag furnace treatment, BAT is to use a combination of the techniques given below. U.K.

	Technique
a	Dust suppression techniques such as a water spray for handling, storage and crushing of the final slag
b	Operation of the furnace under negative pressure
c	Enclosed furnace
d	Housing, enclosure and hood to collect and transfer the emissions to an abatement system
e	Covered launder

BAT 33. In order to reduce diffuse emissions from anode casting in primary and secondary copper production, BAT is to use one or a combination of the techniques given below. U.K.

	Technique
a	Use an enclosed tundish
b	Use a closed intermediate ladle
c	Use a hood, equipped with an air extraction system, over the casting ladle and over the casting wheel

BAT 34. In order to reduce diffuse emissions from electrolysis cells, BAT is to use one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Addition of surfactants to the electrowinning cells	Generally applicable
b	Use covers or a hood to collect and transfer the emissions to an abatement system	Only applicable for electrowinning cells or refining cells for low-purity anodes. Not applicable when the cell needs to remain uncovered to maintain the cell temperature at workable levels (approximately 65 °C)
c	Closed and fixed pipelines for transferring the electrolyte solutions	Generally applicable
d	Gas extraction from the washing chambers of the cathode stripping machine and anode scrap washing machine	Generally applicable

BAT 35. In order to reduce diffuse emissions from the casting of copper alloys, BAT is to use one or a combination of the techniques given below. U.K.

a Description of the technique is given in Section 1.10.
	Technique
a	Use enclosures or hoods to collect and transfer the emissions to an abatement system
b	Use covering for the melts in holding and casting furnaces
c	Boosted suction systema

BAT 36. In order to reduce diffuse emissions from non-acid and acid pickling, BAT is to use one of the techniques given below. U.K.

	Technique	Applicability
a	Encapsulate the pickling line with a solution of isopropanol operating in a closed circuit	Only applicable for pickling of copper wire rod in continuous operations
b	Encapsulate the pickling line to collect and transfer the emissions to an abatement system	Only applicable for acid pickling in continuous operations

1.2.3.2. Channelled dust emissions U.K.

Descriptions of the techniques mentioned in this section are given in Section 1.10.

The BAT-associated emission levels are all given in Table 3.

BAT 37. In order to reduce dust and metal emissions to air from the reception, storage, handling, transport, metering, mixing, blending, crushing, drying, cutting and screening of raw materials, and the pyrolytic treatment of copper turnings in primary and secondary copper production, BAT is to use a bag filter. U.K.

BAT 38. In order to reduce dust and metal emissions to air from concentrate drying in primary copper production, BAT is to use a bag filter. U.K.

Applicability U.K.

In the event of a high organic carbon content in the concentrates (e.g. around 10 wt-%), bag filters may not be applicable (due to blinding of the bags) and other techniques (e.g. ESP) may be used.

BAT 39. In order to reduce dust and metal emissions to air (other than those that are routed to the sulphuric acid or liquid SO₂ plant or power plant) from the primary copper smelter and converter, BAT is to use a bag filter and/or a wet scrubber. U.K.

BAT 40. In order to reduce dust and metal emissions to air (other than those that are routed to the sulphuric acid plant) from the secondary copper smelter and converter and from the processing of secondary copper intermediates, BAT is to use a bag filter. U.K.

BAT 41. In order to reduce dust and metal emissions to air from the secondary copper holding furnace, BAT is to use a bag filter. U.K.

BAT 42. In order to reduce dust and metal emissions to air from copper-rich slag furnace processing, BAT is to use a bag filter or a scrubber in combination with an ESP. U.K.

BAT 43. In order to reduce dust and metal emissions to air from the anode furnace in primary and secondary copper production, BAT is to use a bag filter or a scrubber in combination with an ESP. U.K.

BAT 44. In order to reduce dust and metal emissions to air from anode casting in primary and secondary copper production, BAT is to use a bag filter or, in the case of off-gases with a water content close to the dew point, a wet scrubber or a demister. U.K.

BAT 45. In order to reduce dust and metal emissions to air from a copper melting furnace, BAT is to select and feed the raw materials according to the furnace type and the abatement system used and to use a bag filter. U.K.

Table 3

BAT-associated emission levels for dust emissions to air from copper production

a As an average over the sampling period.
b As a daily average or as an average over the sampling period.
c As a daily average.
d Dust emissions are expected to be towards the lower end of the range when emissions of heavy metals are above the following levels: 1 mg/Nm3 for lead, 1 mg/Nm3 for copper, 0,05 mg/Nm3 for arsenic, 0,05 mg/Nm3 for cadmium.
e When the concentrates used have a high organic carbon content (e.g. around 10 wt-%), emissions of up to 10 mg/Nm3 can be expected.
f Dust emissions are expected to be towards the lower end of the range when emissions of lead are above 1 mg/Nm3.
g The lower end of the range is associated with the use of a bag filter.
h Dust emissions are expected to be towards the lower end of the range when emissions of copper are above 1 mg/Nm3.
Parameter	BAT	Process	BAT-AEL (mg/Nm3)
Dust	BAT 37	Reception, storage, handling, transport, metering, mixing, blending, crushing, drying, cutting and screening of raw materials, and the pyrolytic treatment of copper turnings in primary and secondary copper production	2-5a d
	BAT 38	Concentrate drying in primary copper production	3-5b d e
	BAT 39	Primary copper smelter and converter (emissions other than those that are routed to the sulphuric acid or liquid SO2 plant or power plant)	2-5c d
	BAT 40	Secondary copper smelter and converter and processing of secondary copper intermediates (emissions other than those that are routed to the sulphuric acid plant)	2-4b d
	BAT 41	Secondary copper holding furnace	≤ 5a
	BAT 42	Copper-rich slag furnace processing	2-5a f
	BAT 43	Anode furnace (in primary and secondary copper production)	2-5b f
	BAT 44	Anode casting (in primary and secondary copper production)	≤ 5-15b g
	BAT 45	Copper melting furnace	2-5b h

The associated monitoring is in BAT 10.

1.2.3.3. Organic compound emissions U.K.

BAT 46. In order to reduce organic compound emissions to air from the pyrolytic treatment of copper turnings, and the drying, smelting and melting of secondary raw materials, BAT is to use one of the techniques given below. U.K.

a Descriptions of the techniques are given in Section 1.10.
	Techniquea	Applicability
a	Afterburner or post-combustion chamber or regenerative thermal oxidiser	The applicability is restricted by the energy content of the off-gases that need to be treated, as off-gases with a lower energy content require a higher fuel use
b	Injection of adsorbent in combination with a bag filter	Generally applicable
c	Design of furnace and the abatement techniques according to the raw materials available	Only applicable to new furnaces or major upgrades of existing furnaces
d	Select and feed the raw materials according to the furnace and the abatement techniques used	Generally applicable
e	Thermal destruction of TVOC at high temperatures in the furnace (> 1 000 °C)	Generally applicable

BAT-associated emission levels: See Table 4.

Table 4

BAT-associated emission levels for emissions to air of TVOC from the pyrolytic treatment of copper turnings, and the drying, smelting and melting of secondary raw materials

a As a daily average or as an average over the sampling period.
b The lower end of the range is associated with the use of a regenerative thermal oxidiser.
Parameter	BAT-AEL (mg/Nm3)a b
TVOC	3-30

The associated monitoring is in BAT 10.

BAT 47. In order to reduce organic compound emissions to air from solvent extraction in hydrometallurgical copper production, BAT is to use both of the techniques given below and to determine the VOC emissions annually, e.g. through mass balance. U.K.

	Technique
a	Process reagent (solvent) with lower steam pressure
b	Closed equipment such as closed mixing tanks, closed settlers and closed storage tanks

BAT 48. In order to reduce PCDD/F emissions to air from the pyrolytic treatment of copper turnings, smelting, melting, fire refining and converting operations in secondary copper production, BAT is to use one or a combination of the techniques given below. U.K.

a Descriptions of the techniques are given in Section 1.10.
	Technique
a	Select and feed the raw materials according to the furnace and the abatement techniques used
b	Optimise combustion conditions to reduce the emissions of organic compounds
c	Use charging systems, for a semi-closed furnace, to give small additions of raw material
d	Thermal destruction of PCDD/F in the furnace at high temperatures (> 850 °C)
e	Use oxygen injection in the upper zone of the furnace
f	Internal burner system
g	Post-combustion chamber or afterburner or regenerative thermal oxidisera
h	Avoid exhaust systems with a high dust build-up for temperatures > 250 °C
i	Rapid quenchinga
j	Injection of adsorption agent in combination with an efficient dust collection systema

BAT-associated emission levels: See Table 5.

Table 5

BAT-associated emission levels for PCDD/F emissions to air from the pyrolytic treatment of copper turnings, smelting, melting, fire refining and converting operations in secondary copper production

a As an average over a sampling period of at least six hours.
Parameter	BAT-AEL (ng I-TEQ/Nm3)a
PCDD/F	≤ 0,1

The associated monitoring is in BAT 10.

1.2.3.4. Sulphur dioxide emissions U.K.

Descriptions of the techniques mentioned in this section are given in Section 1.10.

BAT 49. In order to reduce SO₂ emissions (other than those that are routed to the sulphuric acid or liquid SO₂ plant or power plant) from primary and secondary copper production, BAT is to use one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Dry or semi-dry scrubber	Generally applicable
b	Wet scrubber	Applicability may be limited in the following cases: very high off-gas flow rates (due to the significant amounts of waste and waste water generated) in arid areas (due to the large volume of water necessary and the need for waste water treatment)
c	Polyether-based absorption/desorption system	Not applicable in the case of secondary copper production. Not applicable in the absence of a sulphuric acid or liquid SO2 plant

BAT-associated emission levels: See Table 6.

Table 6

BAT-associated emission levels for SO₂ emissions to air (other than those that are routed to the sulphuric acid or liquid SO₂ plant or power plant) from primary and secondary copper production

a As a daily average or as an average over the sampling period.
b In the case of using a wet scrubber or a concentrate with a low sulphur content, the BAT-AEL can be up to 350 mg/Nm3.
Parameter	Process	BAT-AEL (mg/Nm3)a
SO2	Primary copper production	50-500b
	Secondary copper production	50-300

The associated monitoring is in BAT 10.

1.2.3.5. Acid emissions U.K.

BAT 50. In order to reduce acid gas emissions to air from exhaust gases from the electrowinning cells, the electrorefining cells, the washing chamber of the cathode stripping machine and the anode scrap washing machine, BAT is to use a wet scrubber or a demister. U.K.

1.2.4. Soil and groundwater U.K.

BAT 51. In order to prevent soil and groundwater contamination from copper recovery in the slag concentrator, BAT is to use a drainage system in cooling areas and a correct design of the final slag storage area to collect overflow water and avoid fluid leakage. U.K.

BAT 52. In order to prevent soil and groundwater contamination from the electrolysis in primary and secondary copper production, BAT is to use a combination of the techniques given below. U.K.

	Technique
a	Use of a sealed drainage system
b	Use of impermeable and acid-resistant floors
c	Use of double-walled tanks or placement in resistant bunds with impermeable floors

1.2.5. Waste water generation U.K.

BAT 53. In order to prevent the generation of waste water from primary and secondary copper production, BAT is to use one or a combination of the techniques given below. U.K.

	Technique
a	Use the steam condensate for heating the electrolysis cells, to wash the copper cathodes or send it back to steam boiler
b	Reuse the water collected from the cooling area, flotation process and hydro transportation of final slag in the slag concentration process
c	Recycle the pickling solutions and the rinse water
d	Treat the residues (crude) from the solvent extraction step in hydrometallurgical copper production to recover the organic solution content
e	Centrifuge the slurry from cleaning and settlers from the solvent extraction step in hydrometallurgical copper production
f	Reuse the electrolysis bleed after the metal removal stage in the electrowinning and/or the leaching process

1.2.6. Waste U.K.

BAT 54. In order to reduce the quantities of waste sent for disposal from primary and secondary copper production, BAT is to organise operations so as to facilitate process residues reuse or, failing that, process residues recycling, including by using one or a combination of the techniques given below. U.K.

	Technique	Applicability
a	Recover metals from the dust and slime coming from the dust abatement system	Generally applicable
b	Reuse or sell the calcium compounds (e.g. gypsum) generated by the abatement of SO2	Applicability may be restricted depending on the metal content and on the availability of a market
c	Regenerate or recycle the spent catalysts	Generally applicable
d	Recover metal from the waste water treatment slime	Applicability may be restricted depending on the metal content and on the availability of a market/process
e	Use weak acid in the leaching process or for gypsum production	Generally applicable
f	Recover the copper content from the rich slag in the slag furnace or slag flotation plant
g	Use the final slag from furnaces as an abrasive or (road) construction material or for another viable application	Applicability may be restricted depending on the metal content and on the availability of a market
h	Use the furnace lining for recovery of metals or reuse as refractory material
i	Use the slag from the slag flotation as an abrasive or construction material or for another viable application
j	Use the skimming from the melting furnaces to recover the metal content	Generally applicable
k	Use the spent electrolyte bleed to recover copper and nickel. Reuse the remaining acid to make up the new electrolyte or to produce gypsum
l	Use the spent anode as a cooling material in pyrometallurgical copper refining or remelting
m	Use anode slime to recover precious metals
n	Use the gypsum from the waste water treatment plant in the pyrometallurgical process or for sale	Applicability may be restricted depending on the quality of the generated gypsum
o	Recover metals from sludge	Generally applicable
p	Reuse the depleted electrolyte from the hydrometallurgical copper process as a leaching agent	Applicability may be restricted depending on the metal content and on the availability of a market/process
q	Recycle copper scales from rolling in a copper smelter	Generally applicable
r	Recover metals from the spent acid pickling solution and reuse the cleaned acid solution